8011767 OI VICOTEC 450 en V2-2 2013-02 - SICK

O P E R A T I N G I N S T R U C T I O N S

DescriptionInstallationOperation

VICOTEC450Visibility Measurement System

Document Information

ProductProduct name: VICOTEC450

Document IDTitle: Operating Instructions VICOTEC450Order No.: 8011767Version: 2.3Release: 2014-06

ManufacturerSICK AGErwin-Sick-Str. 1 · 79183 Waldkirch · GermanyPhone: +49 7641 469-0Fax: +49 7641 469-11 49E-mail: [email protected]

Place of ManufactureSICK Engineering GmbHBergener Ring 27 · 01458 Ottendorf-Okrilla · Germany

TrademarksWindows is a trademark of the Microsoft Corporation. Other product names used in this document may also be trade-marks and are only used for identification purposes.

Guarantee InformationSpecified product characteristics and technical data do not serve as guarantee declarations.

© SICK AG. All rights reserved.

2 VICOTEC450 · Operating Instructions · 8011767 V 2.3 · © SICK AG

Warning Symbols

Warning Levels / Signal Words

DANGERRisk or hazardous situation which will result in severe personal injury or death.

WARNINGRisk or hazardous situation which could result in severe personal injury or death.

CAUTIONHazard or unsafe practice which could result in personal injury or property damage.

NOTICEHazard which could result in property damage.

Information Symbols

Hazard (general)

Hazard by voltage

Hazard by laser radiation

Important technical information for this product

Supplementary information

Link to information at another place

VICOTEC450 · Operating Instructions · 8011767 V 2.3 · © SICK AG 3

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1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.1.1 Hazards through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.1.2 Hazards through laser beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.3.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.3.2 Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 Using the VICOTEC450 for safety-critical measuring tasks . . . . . . . . . . . . . . . . . . . . . . (fire detection and signalisation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 VICOTEC450 mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.1.1 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.1.2 Scattered light measurement principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.1.3 Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1.4 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Device components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.2.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.2.2 Communication between measuring unit and control unit . . . . . . . . . . . . . . . . . . . . 182.2.3 VCME measuring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.2.4 MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.2.5 Fastening set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.1 Planning steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.2 Determining measuring locations and measuring unit arrangement in the

tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.3 Installation locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.1.4 Air intake and exhaust air hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.1.5 Connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.2.1 Installing the measuring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.2.2 Installing the air inlet with protective grating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.2.3 Installing the control unit with wall housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.2.4 Installing the connection box option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.2.5 Installing the temperature sensor of the temperature measurement option . . . . 36

3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.3.1 General information, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.3.2 Connecting the control unit with wall housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383.3.3 Connecting the control unit in 19” rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.3.4 Connecting the measuring unit(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.3.5 Terminating the VCME - MCU connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483.3.6 Bus addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49


Content

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4 Startup and Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.1.2 Installing the SOPAS ET operating and parameter program . . . . . . . . . . . . . . . . . . . . 524.1.3 Connecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.1.3.1 Configuring the interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554.1.3.2 Connecting using the "Network Scan Assistant" directory . . . . . . . . . . . . . . . . . . 574.1.3.3 Connecting using the "Connection Wizard" menu (valid as from SOPAS ET

Version 02.32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.1.3.4 Selecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604.1.4 Information on using the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614.1.5 Online Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4.2 Customizing the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.2.1 Assigning the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.2.2 Activating connected measuring units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.2.3 Assigning the measuring system to the installation location . . . . . . . . . . . . . . . . . . . 654.2.4 Defining the check cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664.2.5 Configuring the analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674.2.6 Configuring the analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694.2.7 Configuring the limit value relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704.2.8 Calibrating for dust concentration measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714.2.9 Setting the response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734.2.10 Flow measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734.2.11 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744.2.12 Starting normal measuring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.3 Configuring optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3.1 Configuring analog and digital output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3.1.1 Optional analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3.1.2 Optional digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774.3.1.3 Assigning and configuring limit value switches to optional digital outputs . . . . 794.3.2 Configuring optional Interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804.3.2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804.3.2.2 Configuring the Ethernet module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.4 Operating/configuring via the LC-Display option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844.4.1 General information on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844.4.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.4.3 Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.4.3.1 MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.4.3.2 Measuring unit (when setting to measure the dust concentration) . . . . . . . . . . 874.4.4 Using SOPAS ET to modify display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.2 Maintaining the measuring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 935.2.1 Inspection work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 935.2.2 Cleaning the optical boundary surfaces of laser module and receiver . . . . . . . . . . 935.2.3 Cleaning the coarse filter in the air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945.2.4 Replacing the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5.3 Putting out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95


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6 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

6.2 Measuring unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996.2.1 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996.2.2 Warning and error messages in SOPAS ET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996.2.3 Replacing the fuse for the optional power supply unit . . . . . . . . . . . . . . . . . . . . . . . 100

6.3 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016.3.1 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016.3.2 Warning and error messages in SOPAS ET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016.3.3 Replacing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

7.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

7.2 Dimensions, Part Nos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077.2.1 Measuring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077.2.2 Air inlet with protective grating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087.2.3 Cover with integrated air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1097.2.4 Cover for connections option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1107.2.5 Optional installation plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1117.2.6 MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1127.2.7 Optional connection box for connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7.3 Installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1147.3.1 Air intake and exhaust air hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1147.3.2 Connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1147.3.3 Fastening sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157.4.1 VCME measuring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157.4.2 MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157.4.3 Accessories for device check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.5 Consumable parts for 2-year operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

7.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

7.7 Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117


Important information

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VICOTEC450

1 Important information

Main hazards

Intended use

Responsibility of user

Using the VICOTEC450 for safety-critical measuring tasks (fire detection andsignalisation)



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1 . 1 Main hazards

1.1.1 Hazards through electrical equipmentThe VICOTEC450 measuring system is operational equipment for use in industrial highvoltage plants.

1.1.2 Hazards through laser beamThe measuring unit of the VICOTEC450 contains a class 2 laser (eye-safe).

1 . 2 Intended use

Purpose of the device

The VICOTEC450 measuring system serves for continuous visibility measurement in traffictunnels.

Correct use

Use the device only as described in these Operating Instructions. The manufacturer bears no responsibility for any other use.

Observe all measures necessary for conservation of value, e.g. for maintenance and inspection and/or transport and storage.

⊗ Do not remove, add or modify any components to or on the device unless described and specified in the official manufacturer information. Otherwise

– the device could become dangerous

– the manufacturer’s warranty becomes void.

.

WARNING: Danger through mains voltage Disconnect mains lines before working on mains connections or parts

carrying mains voltage. Refit any contact protection removed before switching the mains voltage

back on again.

WARNING: Hazards through laser beam⊗ Never look directly into the beam path⊗ Do not point the laser beam at persons Prevent damaging reflections of the laser beam by reflective parts Do not operate the laser module outside the measuring unit.



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1 . 3 Responsibility of user

1.3.1 General information

Designated users

The VICOTEC450 measuring system may only be operated by skilled technicians who,based on their technical training and knowledge as well as knowledge of the relevantregulations, can assess the tasks given and recognize the hazards involved.

Special local conditions

Observe the valid legal regulations as well as the technical rules deriving from imple-mentation of these regulations applicable for the respective equipment during work preparation and performance.

Carry out work according to the local conditions specific for the equipment as well as operational hazards and regulations.

Retention of documents

Keep the Operating Instructions belonging to the measuring system as well as equipmentdocumentation onsite for reference at all times. Pass the respective documentation on toany new owner of the measuring system.

1.3.2 Safety information and protective measures

Protection devices

Preventive measures for operating safety

Recognizing malfunctions

Every deviation from normal operation is to be regarded as a serious indication of afunctional impairment. These are, amongst others:

● Warning displays (e.g. heavy contamination)

● Significant drifts in measured results

● Increased power consumption

● Higher temperatures of system components

● Monitoring devices triggering

● Smells or smoke emission

NOTICE:Suitable protection devices and safety equipment for persons must be available according to the respective hazard potential and be used by the personnel.

NOTICE:The user must ensure that: Neither failures nor erroneous measurements can lead to operational

states that can cause damage or become dangerous The specified maintenance and inspection tasks are carried out regularly

by qualified, experienced personnel.



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Avoiding damage

1 . 4 Using the VICOTEC450 for safety-critical measuring tasks(fire detection and signalisation)The plant operator is always responsible for plant safety. Special attention should be paidto the following points:

● Plants with safety risks must always be redundantly monitored by suitable metrological equipment. Therefore the VICOTEC450 may not be used as the only link in a safety chain.

● The operator is always responsible for any switching thresholds or definition of switch-ing criteria.

● Precautions have to be taken in good time to ensure safe operation of the plant during times when the VICOTEC450 is not available (e.g. during maintenance or repair).

● SICK does not assume any liability for damage resulting from a possible device mal-function.

NOTICE:The operator must ensure the following to avoid malfunctions that can indirectly or directly lead to injuries to persons or material damage: The responsible maintenance personnel are present at any time and as

fast as possible The maintenance personnel are adequately qualified to react correctly to

malfunctions of the measuring system and any resulting operational interruptions (e.g. when used for measurement and control purposes)

The malfunctioning equipment is switched off immediately in case of doubt and that switching off does not cause collateral malfunctions.


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VICOTEC450

2 Product Description

VICOTEC450 mode of operation

Device components


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2 . 1 VICOTEC450 mode of operation

2.1.1 Functional principleThe VICOTEC450 runs as extractive system with in-situ measurement features.

Version with fog elimination.

An air flow is suctioned from the traffic area in the tunnel via an air intake hose and thenfed to a heating chamber where it is heated to the point where any existing water drops(fog) are vaporized. The measuring air is fed to the measuring cell in which the scatteredlight intensity, as measure for the visibility, is determined using a laser. The measuring airis conveyed by a blower. An air filter is fitted before the blower to prevent deposits in theblower and to lengthen its service life. Apart from that, a partial flow of the clean air isguided to the optics to keep these clean. The air flow rate is set at the factory andcontinuously monitored by an integrated flow rate measurement.

Figure 1 VICOTEC450 basic layout (shown with fog elimination)

Tunnel traffic area VCME measuring unit

24 V DC

3

4

6

7

9

11

1 2

A

B

C

D

E

90 ... 250 V AC

MCU control unit

5

8

10

Δ p ≈ 0

1 Air inlet2 Air intake hose3 Heating chamber4 Measuring cell5 Laser6 Receiver7 Air filter8 Purge air9 Blower

10 Processor board11 Exhaust air hose

A Analog output 0 ... 20 mAB Relay outputsC Analog inputsD Digital inputsE Interface for control system


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Version without fog elimination

In some cases, it can be necessary to include fog in the measurement. To realize this, theair sucked from the tunnel traffic area is first passed to the measuring chamber. The air isthen passed to the heating chamber and then on to the air filter and blower. Heating themeasuring air prevents moisture making the air filter ineffective in a short time.

Figure 2 Basic layout of a measuring unit without fog elimination

MCU control unit

1 Air inlet2 Air intake hose3 Measuring cell4 Heating chamber5 Air filter6 Blower7 Exhaust air hose

Tunnel traffic area VCME measuring unit

12

4

3

5

6

7


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2.1.2 Scattered light measurement principleThe VICOTEC450 operates according to the scattered light measurement principle (forwardscattering). The extreme sensitivity of this principle makes it particularly suitable formeasuring very small particle concentrations.

Figure 3 Scattered light measurement principle

A laser diode beams the dust particles in the measuring air flow with modulated light in thevisual range (wavelength approx. 650 nm). The light scattered by the particles is recordedby a highly sensitive detector, electrically amplified and passed to the measuring channelof a microprocessor as central part of the measuring, control and evaluation electronics.The measuring volume in the measuring cell is defined by the intersection between thetransmitted beam and the receiver aperture.

The smallest brightness changes of the laser beam emitted are detected by continuousmonitoring of the sender level (partial beam to monitor receiver) and then used duringmeasuring signal determination

The primary measured variable of scattered light intensity is almost proportional to particleconcentration. The scattered light intensity is converted in the device to the k value usedfor visibility measurement which is then output as the measured value. The basis is afactory calibration of the VICOTEC450 with the transmission meter normally used.

Laser diode

Detector

Measuring volume


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2.1.3 Response timeThe response time is the time taken to reach 90% of the signal peak after a sudden changein the measuring signal. The response time is freely adjustable between 1 ... 600 s. Settinga higher response time provides better attenuation of transient fluctuations in themeasured value and malfunctions to produce a "smoother" output signal.

Figure 4 Response time

2.1.4 Function checkA check cycle can be triggered at fixed intervals as from a definable starting timepoint foran automatic function check of the measuring system. The setting can be made usingSOPAS ET (→ p. 66, §4.2.4). Any unallowed deviations from normal behavior that may occurare signaled as errors. A check cycle triggered manually can help localize possible errorcauses should a device malfunction occur.

A check cycle runs for approx. 120 s and is split into approx. 30 s measurement ofcontamination on optical surfaces and 90 s (default value) output of values determined.

Value(k value)

90% of the signal peak

Measured value with response time

Process change

Response time

t in s10 20 30 40 50 60 70 80 90

● The duration can be set as a parameter (→ p. 66, §4.2.4).● The analog output must be activated to output check values on the analog

output (→ p. 67, §4.2.5).● The value measured last is output on the analog output during control

value determination.● If the check values are not output on the analog output, the current

measured value is output when control value determination has completed.● Relay 3 is activated during a check cycle (→ p. 40, Fig. 27).● A check cycle is not started automatically when the measuring system is in

"Maintenance" mode.● "Function control" is displayed on the Display module (option) of the control

unit during the check cycle.● If the start timepoint or cycle interval are changed, a check cycle timed

between parameter setting and new start timepoint is still carried out.● Changes to the interval time are first effective after the next start

timepoint.


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Contamination measurement

The receiver is moved completely through the laser beam in order to measure thecontamination on the optical boundary surfaces. The light emitted by the laser diode istherefore measured directly. The intensity value measured during the swivel movement iscomputed with the factory setting to a correction factor. This fully compensates anycontamination that occurs.

If the contamination value is lower than 50%, an analog value in a range between Live Zeroand 20 mA and proportional to the contamination value is output during the check cycleotherwise the output current for device status "Malfunction" is always output (→ p. 67,§4.2.5).

Figure 5 Contamination measurement

1 2 3 4 5

6 7 8 91 Laser module2 Aperture 13 Aperture 24 Receiver in measuring position5 Light trap6 Measuring cell7 Reference position at cycle start8 Reference position at cycle end9 Guideway


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2 . 2 Device components

2.2.1 System overviewThe measuring system comprises the following components:

● VCME measuring unitfor signal recording, signal processing and controlling device functions

● MCU control unitfor control, evaluation and output of the data of max. 8 sensors connected via RS485 interface

● Air inlet with protective grating

Alternative:

● Cover for connections with integrated air inlet

● Air intake and exhaust air hoses (set, lengths 5 m, 10 m, 15 m)

● Connection cable to connect the measuring unit to the MCU (lengths 5 m, 10 m, 50 m, other lengths on request)

● Option, cover for connections

● Option, installation plate for measuring unit

● Option, connection box for bus wiring

Figure 6 VICOTEC450 components

1 2

5 6

3 4

1 VCME measuring unit2 MCU control unit3 Exhaust air hose4 Air intake hose5 Connection cable6 Power cable7 Air inlet with protective grating and coarse

filter8 Cover for connections option9 Cover for connections with integrated air inlet

7

8

9


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2.2.2 Communication between measuring unit and control unit

Standard variant

In this version, one measuring unit is connected to one control unit using the connectioncable.

Figure 7 MCU - VCME standard connection

Bus variant

In this version, up to 8 measuring units can be connected to one control unit via the RS485interface. The measuring units must be provided with mains voltage separately in thiscase. The optional power supply unit must be installed in the measuring unit for thispurpose.

Figure 8 MCU - VCME bus connection

2.2.3 VCME measuring unitThe measuring unit analyzes the particle concentration in the air extracted from the tunneltraffic area as measure for the visibility prevailing in the tunnel.

The measuring unit comprises the components (→ p. 19, Fig. 9):

● Measuring cell

● Laser module

● Processor board

● Heating chamber for fog damping

● Blower with air filter

● Flow measurement

● Housing for wall fitting, material 1.4571, coated gray (RAL7042)

When the measuring unit is installed as single connection to the control unit (→ Fig. 7), themeasuring unit is provided with 24 V DC from the power supply unit in the control unit viathe connection cable.

For larger distances (→ p. 31, §3.1.5) or bus connection, integrate an optional power supplyunit in the measuring unit.

VCME MCU

Mains voltage

VCME2

VCME4

VCME8

VCME1

VCME3MCU

AB 2 AB 4 AB 8AB 1 AB 3

Mains voltage Bus line AB = Optional connection box


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Figure 9 VCME measuring unit

Flow measurement

The air flow rate through the measuring unit is monitored and controlled by a module with adifferential pressure Sensor module. Cross-section reductions in the air intake line bydeposits or other causes are detected reliably and included in the regulation of the air flowrate. This increases the functional reliability of the measuring system and reducesmaintenance frequency.

1 2 3 4 5

1 Air outlet connection2 Connection for mains cable

when using the optional power supply unit

3 Connection for connectioncable to MCU

4 Air inlet connection5 Connection for optional

temperature sensor (2x)6 Laser module7 Heating chamber8 Measuring cell8 Receiver

10 Swivel mechanism11 Flow measurement12 Air filter13 Blower14 Processor board

6 7 8 9 10 11

12 13 14


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Accessories

1 Air inlet with protective grating Subassembly for freely selectable position of the air intake opening in the traffic area of the tunnel. The air intake hose serves as connection to the air inlet connection in the measuring unit. The layout depends on the installation location (on the tunnel wall or intermediate ceiling). An integrated filter prevents coarse particles or insects entering the air intake hose.

2 Air intake and exhaust air hoses (set, lengths 5 m, 10 m, 15 m) Air intake hose made of silicone (flexible), inner diameter 13 mm (outer diameter 19 mm); exhaust air hose made of synthetic material, inner diameter 25 mm.

3 Cover for connections with integrated air inletThis component combining the air inlet with protective grating, a very short air intake line and the optional cover for connections allows very easy assembly in the tunnel traf-fic area and protects the VCME connections against damage during tunnel cleaning using wash brushes.

4 Connection cable to connect the measuring unit to the MCU (lengths 5 m, 10 m, 50 m)4-pole screened cable with socket for connection to the plug on the measuring unit and cable ends for connection to the terminals in the MCU.

Options

1 Cover for connectionsPlan this option when the measuring unit is to be fitted in the traffic area and the cover with integrated air inlet cannot be used. It protects the VCME connections during tunnel cleaning with wash brushes so that the measuring unit does not have to be dismantled during cleaning.

2 Temperature measurement with thermal element Ni-Cr-Ni, line 20 m (standard length) and electronic control

This option can be used with longer air intake lines (using the air inlet with protective screen subassembly) to measure the temperature at the suction location in addition to the air temperature measurement integrated in the VCME. Installing further tempera-ture measurement units allows early fire detection by monitoring the temperature at various locations in the traffic area.

3 Power supply unit 24 V DC, 75 WServes separate power supply to the measuring unit when the distance between the measuring unit and the MCU is too large (voltage loss too high in the line) or when sev-eral measuring units are connected to one MCU (bus variant)

Other lengths on request.

Measuring range: - 50 ... +250 °C

Accuracy (not calibrated): ± 2 K (resolution ± 0.25 K)


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4 Installation plate Serves to fit and remove the measuring unit at the installation location simply and con-veniently without tools. The measuring unit can also be secured with a lock.

Type code

The following type codes identify the various selection options:

Options 2, 3 and 4 can only be integrated in the measuring unit at the factory. Send the measuring unit to the manufacturer when these options are to be fitted later.

Type key for measuring unit VCME-XX-P-X-X-X

Power supply- 24: 24 V DC. from MCU- WR: 90 ... 250 V AC with separate power supply unit 24 V DC 75 WFlow measurement- P: With differential pressure sensor

Optional temperature measurement with number of measuring points- 0: Without- n: With thermoelement Ni-Cr-Ni, line 20 m

and electronic control n = 1 or 2

Fog elimination- F: With- N: Without

Misc.- N: Without special features

Example: VCME-24-P-2-F-N

24 V DC from MCU

With flow measurement

With 2x optional temperature measurement

With fog elimination

Without special features


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2.2.4 MCU control unitThe control unit has the following functions:

● Data transfer controlling and processing the data from the sender/receiver unit(s) con-nected via RS485 interface

● Signal output via analog outputs (measured value) and relay outputs (device status)

● Signal input via analog and digital inputs

● Voltage supply for the connected sender/receiver units

● Communication with host control systems via optional modules

Plant and device parameters can be set easily and conveniently via a USB interface using alaptop and a user-friendly operating program. The parameters are stored reliably even inthe case of a power failure.

The control unit is fitted in a steel sheet enclosure as standard.

Standard interfaces

Figure 10 MCU control unit in wall-housing with options

Analog output Analog inputs Relay outputs Digital inputs Communication

1 output 0/2/4...22 mA (electrically isolated, active); for selectable output of measured variables:● k value● Inlet temperature● Visibility● Scattered light intensityOptionally:● Dust concentration● Flow too low ● Temperature external 1x ● Temperature external 2x Resolution 10 bits

2 inputs 0...20 mA (Standard; without electric isolation) Resolution 10 bits

5 changeover contacts (48 V, 1 A) to output status signals● Operation/malfunc-

tion● Maintenance● Check cycle● Maintenance

request● Limit value

4 inputs to connect potential-free contacts (e.g. to connect a maintenance switch or trigger a check cycle)

● USB 1.1 and RS232 (on terminals) for measured value inquiries, setting parameters and software updates.

● RS485 for sensor connection

DISPLAYMODUL

relay 3 relay 4 relay 5 BUS - S/E unit 1BUSTerm

Term

BUS - S/E unit 2

relay 1 relay 2com nc. no. com nc. no. com nc. no. com nc. no. com nc. no.

Res

et

LED

Controlbuttons

Processorboard

Optional Display module Optional Interface module Optional I/O module Optional Display module


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Figure 11 MCU control unit in 19” rack with options

Options

The following options serve to considerably extend the functionality of the MCU:

1 Display moduleModule to display measured values and status information, and for configuring during start-up, selection via control buttons.

– Displays

SICKMULTI CONTROL UNITPOWER

FAILURE

MAINTENANCEREQUEST

INTERFACE-MODULEI/O-MODULE

POWER

ERROR

TxD RxD

Plug-in slots for optional I/O modules Display module option

Backplane with terminal connection for wiring by customer

Power supply unit Plug-in slot for Interface module option

Type Display

LED

Power (green) Voltage supply OK

Failure (red) Function fault

Maintenance request (yellow)

Maintenance request

LC display Graphic display (main screen)

– Scattered light intensity– Inlet temperature– Heater temperature– Temperature external 1x – Temperature external 2x – Dust concentration– k value– Visibility

Text display2 measured values (see graphic display) and 8 diagnosis values (→ p. 85, Fig. 80)


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The graphic display shows two main measured values of a measuring unit selected at the factory or computed values from the MCU as bar charts. Alternatively, up to 8 single measured values of a measuring unit can be displayed (toggle with "Meas" button).

Figure 12 LC-Display with graphic (left) and text (right) display (example)

– Control buttons

2 I/O moduleFor plugging on module carriers (MCU in wall housing) or in plug-in module (MCU in 19” rack), communication via I²C bus, optionally as:

– 2x analog output 0/4 ... 22 mA to output further measured variables (load 500 Ω)

– 2x analog input 0/4 ... 22 mA to read in values from external sensors

– 4x digital input for connection of galv. isolated contacts

– 2x digital output (changeover contacts, capacity 48 V AC/DC, 5 A)

– 4x digital output (NO contacts, capacity 48 V AC/DC, 0.5 A)

3 Interface moduleModule to pass measured values, system status and service information to higher level control systems, optional for Profibus DP-V0 or Ethernet, to plug onto hat rail (MCU in wall-housing) or to plug-in slot (MCU in 19” rack). The module is connected to the con-nection board by an associated cable.

Button Function

Meas● Toggle between text and graphic display● Display the contrast setting (after 2.5 s)

Arrows Select next/previous measured value screen

Diag Display alarm or error message

Menu Display main menu and call up submenus

● One module carrier is necessary for each module (to insert on top hat rail). One module carrier has to be connected to the processor board with a special cable, other module carriers can be docked to it.

● Max. 8 I/O modules can be plugged, max. 4 modules of these may be the same type.

Profibus DP-V0 to transfer via RS485 in accordance with DIN 19245 Part 3 as well as IEC 61158.


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Type code

The following type code defines the various configuration options in the same manner asfor the measuring unit:

Type code control unit: MCU-N X X X N X X X X X X N N E

Integrated purge air supply - N: Without

Power supply- W: 90 ... 250 V AC - 2: Optional 24 V DC

Housing variants- G: Wall housing grey - S: Wall housing, stainless steel 1.4571 (coated grey)- R: 19" housing

Display module- N: Without- D: With

Other options- N: Without

Optional analog input (plug-in module; 0/4...20 mA; 2 inputs per module)- 0: Without- n: With, n = 1...4 1)

Optional analog output (plug-in module; 0/4...20 mA; 2 outputs per module)- 0: Without- n: With, n = 1...4 1)

Optional digital input (plug-in module; 4 inputs per module)- 0: Without- n: With, n = 1...4 12)

Optional digital output power (plug-in module; 48 V DCC, 5 A; 2 changeover contacts per module)- 0: Without- n: With, n = 1...4 12)

Optional digital output low power (plug-in module; 48 V DC, 0.5 A; 4 NO contact elements per module)- 0: Without- n: With, n = 1...4 1)

Optional Interface module- N: Without- E: Ethernet- P: Profibus

Special versions- N: No special features

EX certification- N: Without EX certification

Software- E: Emission measurement

1): Maximum number of all modules of the same type = 4


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2.2.5 Fastening setVarious fastening sets are available to fasten the measuring unit, control unit and optionalconnection box on the tunnel wall or ceiling. Selection depends on the actualrequirements. The Table below lists the respective parts and their usage options.

Fastening set Usage

Name(Part No.)

Contents Requirements For component Qty. per comp.

4D8-1.4571/PA(2031889)

4x Fischer dowel S104x hexagon woodscrew 8*50 A4

No particular Measuring unit and control unit in wall housing

1

2D4-1.4571/PA(2031890)

2x Fischer dowel S62x round head woodscrew 3.5*40 A4

Connection box option 1

2M8-1.4571(2031891)

2x dowel SLM 8N A42x hexagon screw 8*55 A4

Stainless steel only Measuring unit, control unit and connection box option in stain-less steel housing

2

4M8-1.4529(2031887)

4x Fischer tie bolt FAZ 8/10 C Aggressive ambi-ent air

1

Example: MCU-NWSDN01010PNNE

Not purged,

Wide-range power supply unit,

Stainless steel housing,

With Display module,

Without other options

Without optional analog inputs

With one additional analog output

Without optional digital inputs

With additional digital output power

Without optional digital outputs low power

With Interface module Profibus DP

Without special features

Without EX certification

Emission measurement


Assembly and Installation

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VICOTEC450

3 Assembly and Installation

Project planning

Assembly

Installation



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3 . 1 Project planning

3.1.1 Planning stepsPlan the following before starting assembly and installation work:

Determine the measuring locations.

Select the system components according to usage conditions and customer demands (→ p. 18, §2.2.3 and → p. 22, §2.2.4).

Determine the fitting locations for air inlet with protective grating (when used), measur-ing unit(s) and control unit.

Plan the voltage supply and cabling.

3.1.2 Determining measuring locations and measuring unit arrangement in the tunnel

Measuring locations

The normal criteria for tunnel ventilation are applicable for the distance betweenmeasuring units inside the tunnel when using the VICOTEC450 as visibility measuringdevice. Experienced specialists should plan the details because these depend on manyfactors such as tunnel geometry, location, traffic volume and vehicle mix.

The following values can be used as basis:

● An even spread along the tunnel length for semi and transverse ventilation with at least 2 measuring points per ventilation section.

● At least 3 measuring points in tunnels with one-way traffic (one each approx. 150 m from the entrances, at least one in the middle of the tunnel), according to the German "Richtlinie für die Ausstattung und den Betrieb von Straßentunneln, RABT" for length-ways ventilated tunnels (EU Directive 2004/54/EC Minimum safety requirements in tunnels) because two-way traffic cannot generally be excluded.

Measuring unit arrangement

The measuring units can be installed in the tunnel in the following manner:

If the VICOTEC450 is to be used for smoke detection as well, the distance between two neighboring measuring points which serve as optical smoke detector shall not be larger than 100 m to 150 m. (See RABT2003, Astra modification proposal 2005).

Measuring unit installation Measured air extraction Remarks

Directly in the traffic area on the tunnel wall Via air inlet with protective grating or cover for connec-tions with integrated air inlet (should be preferred due to lower installation effort)

Choose this arrangement when the respective measuring point will not be used to measure fog as visibility impairment. This is often the case for measuring points located less than 150 m from the tunnel portal. Prerequisite is sufficient space in the traffic area.

Tak

VoG

18°

4,2 m/s

- 40° 60°

0

1

3

4

2

1 Tunnel wall2 Control unit3 Measuring unit4 Cover with integrated air inlet



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In recesses, switch cabinets for equipment in the tunnel traffic area, on intermediate ceilings or in operational rooms at an easily accessible location that can be reached without having to close the tunnel.

Via air inlet with protective grating and air intake hose with a maximum length of 30 m

Choose this arrangement when:● There is not enough clearance for in-

situ measuring devices (transmis-sion meter) in the tunnel traffic area

● Fixtures in the traffic area are not possible or desired for other reasons

● Measuring is required at especially inaccessible locations where trans-mission meters cannot be installed.

In operational rooms Via air intake hoses up to 300 m in length with sepa-rate blower as bypass system

Only choose this arrangement when the previous installation options are not possible.Disadvantages:● Much longer response time (long air

intake hose) → particularly impor-tant when using the VICOTEC450 as smoke detector

● High effort for planning, installation and operation (could possibly be higher than the device costs)

● Air intake hoses made from PVC or PE have unfavorable behavior in fire (PVC is not free from Halogen, PE is not self-extinguishing and can therefore spread fires further), and can become charged electrostati-cally → measured values can be falsified through changes in the measured air

● Air intake hoses made of stainless steel to be used preferably for this arrangement cause considerably higher costs

● Dust particles can deposit in the air intake hoses → reduced cross-section

Measuring unit installation Measured air extraction Remarks

Tak

VoG

18°

4,2 m/s

- 40° 60°

0

1

3

4

Max. 30 m

2

1 Control cabinet2 Control unit3 Measuring unit4 Air inlet with protective grating

2

4

1

3

5

67

Max. 300 m

1 Control cabinet2 Control unit3 Measuring unit4 Blower5 Measuring air feed for further evaluation systems (e.g. SIDOR)6 Pipe manifold7 Air filter



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3.1.3 Installation locationsFit measuring and control units at a level, easily accessible and protected location withenough clearance for opening the doors and laying air lines and cables (→ p. 34, §3.2.2 and→ p. 35, §3.2.3). Ensure sufficient distance sideways to passing vehicles when the units aremounted on the tunnel wall in the traffic area.

The extraction location must be in the traffic area, centered on the tunnel ceiling if possiblewhen the VICOTEC450 is used as smoke detector as well.

Install the MCU control unit in an operational room when possible. The maximum distanceto the measuring unit is 1200 m.

Figure 13 Installation locations

3.1.4 Air intake and exhaust air hosesObserve the following requirements:

● Inside diameter of the air intake hose is 13 mm for elastic material and 16 mm for non-elastic material (connection via a flexible hose where appropriate).

● Inside diameter of the exhaust air hose 25 mm.

● Minimal bend radiuses for air intake and exhaust air hoses 200 mm.

● The exhaust air hose must not be much longer than the air intake hose.

● The air pressure at the air intake location and at the location where the VICOTEC450 exhaust air flows back into the environment must be approximately the same.

● The exhaust air must not be led to operational rooms that are under overpressure.

● Air intake and exhaust air hoses must run continuously downwards away from the measuring unit so that no water can collect in the hoses or penetrate the measuring unit. If this cannot be realized, lay the hoses at the extraction location and measuring unit at least straight down for a certain distance (→ Fig. 13 and → p. 31, Fig. 14). The hoses should be as short as possible.

● It may be necessary to install a water separator in case of long air intake hoses, partic-ularly when the hose is laid through areas with different temperatures.

1 2 3 4

5

6

Max. 1200 m

> 1 m

1 MCU control unit2 Operational room3 Installation surface4 VCME measuring unit5 Extraction location (air inlet

with protective grating)6 Tunnel wall

Outer diameter of the air inlet nozzle of the measuring unit 16 mm.



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Figure 14 Connection of air intake and exhaust air hoses when downward slope not available

3.1.5 Connection cableThe connection cable must have an adequate wire cross-section to cope with the powerrequirements for the blower and heating chamber when the MCU feeds the power supply tothe measuring unit. This depends on the cable length.

For distances between the measuring and control units longer than 130 m, it isrecommended, for cost reasons, to connect the measuring unit separately to the mainsvoltage using the optional power supply unit.

SICK can deliver a set comprising the air intake and exhaust air hoses withlengths of 5 m, 10 m and 15 m.

2

3

1

1 Measuring unit2 Exhaust air hose3 Air intake hose

Wire cross-section in mm² Specific resistance in Ω/km Maximum cable length in m

0.5 40 25

0.75 25 40

1.00 18 55

1.5 14 70

2.5 8 130

Minimum voltage for VCME is 20 V DC



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3 . 2 AssemblyAll of the assembly and installation work has to be carried out onsite. This comprisesmounting the measuring and control units, assembling the air inlet with protective gratingand air intake hose (if the cover with integrated air inlet is not used).

3.2.1 Installing the measuring unitFit the measuring unit at a level, easily accessible and protected location.

Figure 15 Measuring unit assembly dimensions

Work to be carried out

Drill the holes as shown in p. 33, Fig. 16 (distances in accordance with Fig. 15).

Insert dowels (fastening set 4D8-1.4571/PA, 2M8-1.4571) or tie bolts (fastening set 4M8-1.4529).

Fasten the measuring unit with the hexagon head screws or nuts.

WARNING: Observe the relevant safety regulations as well as the safety notices in

Section 1 when carrying all assembly work! If possible, only carry out assembly work when the tunnel is closed! Take suitable protective measures against possible hazards!

NOTICE:The connections must always be below.

∅ 8

> 550

215260

> 25

0

340

320

Clearance for opening the door,minimum sideways distance to passing vehicles when mounted on the tunnel wall

Clearance for cables

300



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Figure 16 Drill hole dimensions

Installing the measuring unit using the optional installation plate

Fit the measuring unit in accordance with Fig. 17.

Figure 17 Installing the installation plate option

Fastening set D [mm] T [mm] Remark

2D4-1.4571/PA 6 ≥ 40 The dowel should be flush with the tunnel wall.

4D8-1.4571/PA 10 ≥ 70

2M8-1.4571 12 ≥ 60

4M8-1.4529 8 ≥ 65 The tie bolt must not protrude more than 12 mm from the tunnel wall.

T

D

1 2

3

4

1 Drill hole2 Tunnel wall3 Tie bolt with fastening nut4 Bracket of the measuring unit

We recommend using M10 bolts on the fastening points on which the measuring unit can be positioned and fastened with self-locking nuts.

> 25

0 31

025

Clearance for opening the door, minimum sideways distance to passing vehicles when mounted on the tunnel wall


320

385

> 550

350

355 15

192.5

∅ 10



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Position measuring unit (1) on installation plate (2) so that the lower right bracket (3) lies on safety catch (4), slide upper brackets (5) into the associated recesses (6), and then slide the measuring unit to the left until the safety catch is freely movable, and then secure it.

Figure 18 Fitting the measuring unit on the installation plate

3.2.2 Installing the air inlet with protective grating

Figure 19 Installation dimensions for wall mounting

6

2

5

1

4

3

> 200

95 ∅ 5,5

32

> 25

0

10475

Clearance for the air intake hose

Minimum distance topassing vehicles

75



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Figure 20 Installation dimensions for the air inlet with protective grating on the intermediate ceiling

3.2.3 Installing the control unit with wall housingFit the control unit in a vertical, level, easily accessible and protected location inaccordance with Fig. 21.

Figure 21 Installation dimensions for MCU in steel sheet housing

The respectively suitable fastening sets can be used for fastening (→ p. 26, §2.2.5;installation → p. 33, Fig. 16).

(95)

> 15

0

9575

Clearance for the air intake hose

75∅ 5.5

A

A

> 350

210

120

> 25

0

340

320

∅ 8


Clearance for opening the door,Minimum sideways distance to passing vehicles when fitted on the tunnel wall

160

● The MCU control unit can be installed up to 1200 m away from the measuring unit when a suitable cable is used.

● We recommend installing the MCU in an operational room for trouble-free communication with the VICOTEC450.



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3.2.4 Installing the connection box optionFit this component on a level surface (tunnel wall or roof) as shown in Fig. 22. Therespectively suitable fastening sets can be used for fastening (→ p. 26, §2.2.5; installation →p. 33, Fig. 16).

Figure 22 Installation dimensions for connection box option

3.2.5 Installing the temperature sensor of the temperature measurement optionFit the temperature measurement option with 1x temperature sensor as follows:

● If the air inlet with protective grating option is used, slide the temperature sensor into the screw fitting, and fasten it.

Figure 23 Installing the temperature sensor in the air inlet with protective grating

● If the cover for connections with integrated air inlet option is used, put the temperature sensor into one of the ducts in the bottom of the measuring unit, and fasten it. If both these options (temperature sensor and cover) are clearly assigned to one measuring unit when ordered, the temperature sensor is installed in this measuring unit at the fac-tory.

● Fasten the temperature sensor in immediate proximity of the air intake opening when other air inlets are used.

Install the temperature sensors of the option temperature measurement with 2xtemperature sensor in the traffic area of the tunnel so that optimal temperature monitoringfor early fire detection is possible.


> 150 80> 150

52

M4

113

125

150

176

Aluminium housing Stainless steel housing

M 8

> 150 132> 150

1

2

3

4

1 Air inlet with protective grating2 Screw fitting 3 Temperature sensor4 Connector



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3 . 3 Installation

3.3.1 General information, prerequisitesThe assembly work described in §3.2 must have been completed before startinginstallation work.

All of the installation work must be carried out onsite. This includes:

Complete laying of power supply and signal cables.

Connecting the power supply and signal cables to all system parts.

Installing switches and mains fuses.

Requirements for cable types for onsite connection of measuring and control units

A data line with twisted pairs and common shield is required to connect the measuring andcontrol units. Do not use normal telecommunications cables.

The following cable types are well or very well suited for data transfers:

1 UNITRONIC LiYCY (TP) 4 x 2 x 0.75 mm²Not suitable for underground installation (protected laying required if necessary)

2 UNITRONIC Li2YCY (TP) 4 x 2 x 0.5 mm²Usable as alternative to item 1; not suitable for underground installation (protected lay-ing required if necessary)

3 UNITRONIC Li2YCYv (TP) 4 x 2 x 0.5 mm²Suitable for underground installation

4 Special cable type ASS 4 x 2 x 0.5 mm²Silicone, halogen-free, high heat and cold resistance, cable sheath red (similar to RAL 3000)

5 Accessories: Braided cable sleeving PA-S 4, black, to provide mechanical protection or to cover the sheathing color if necessary.

WARNING: Observe the relevant safety regulations as well as the safety information in

Section 1 when carrying out all installation work! Take suitable protective measures against possible local or plant-specific

hazards.

● Plan adequate cable cross-sections (→ p. 106, §7.1).● When using the optional power supply unit, ensure cable ends of the

connection cable and power cable of the measuring unit are sufficiently long.

● Protect cable plug-in connectors not connected against moisture and dirt (screw cover on).

● Manufacturer of UNITRONIC cables: LAPP-Kabel● Manufacturer of special cable: metrofunk KABEL-UNION GmbH

NOTICE:● We cannot grant any warranty for proper system function when cables

which do not comply with the above specifications are used.● Always use cables of the same type and ensure continuous shielding.



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3.3.2 Connecting the control unit with wall housing

Figure 24 MCU in wall housing

Work to be carried out

Connect the connection cable in accordance with → p. 40, Fig. 27 (standard connection) resp. → p. 41, Fig. 28 (bus variant).

Connect cables for status signals (operation/malfunction, maintenance, check cycle, maintenance request, limit value), analog output, analog and digital inputs according to requirements (Fig. 29, Fig. 30, Fig. 31, → p. 40, Fig. 27 and → p. 41, Fig. 28; only use cables with twisted-pairs and shield).

Connect mains cable to terminals L1, N, PE of the MCU (→ Fig. 24).

Close off unused cable openings with dummy plugs.

Optional I/O modules

Processor board

Terminals for mains connection

Optional Interface module Display module

Connect an onsite cable to a suitable 7-pole socket when used (→ p. 39, Fig. 26; SICK Part No. 7045569)

NOTICE: Only use cables with twisted-pairs and shield (e.g. UNITRONIC LiYCY (TP)

2 x 2 x 0.5 mm² from LAPP-Kabel; not suitable for underground laying).



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MCU processor board connections

Figure 25 MCU processor board connections

Onsite connection cable plug-in connection to MCU

Figure 26 Plug-in connector connection on onsite cable

WARNING: Be sure to check the wiring before switching the supply voltage on. Only modify wiring when disconnected from the mains and potential-free.

1 2 3 4

9 8

10

11

12

5

6

7

1 Supply voltage 24 V DC2 RS2323 Connection for optional I/O

module4 Connection for optional Display

module5 Connection for LEDs6 Connection for optional

Interface module7 USB plug-in connector8 Connections for sender/

receiver unit9 Connections for relays 1 to 5

10 Connections for analog inputs1 and 2

11 Connection for analog output12 Connections for digital inputs

1 to 4

Onsite cable in accordance with p. 37, §3.3.1

ClosedClosed

OpenOpen A

A

A -A

1+24 V

NoteTo open, connect the plug-in connector to the plug on the measuring unit.

2 3RS485 B

4RS485 A

5

6-24 V

7Shield



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MCU - VCME standard connection

Figure 27 MCU - VCME standard connection

MCU processor board

Measuring unit

Plug

Connection cable (SICK cable or onsite cable in accordance with p. 37, §3.3.1

Socket

Whi

teBr

own

Gre

enYe

llow

Whi

teYe

llow

Gre

enBr

own

Plug assignment (View on pin side)

RS485 B 3

RS485 A4

5

6-24 V

2

7

1+24 V

Switching position of the relay contacts in currentless condition

MaintenanceCheck cycle

Ope

ratio

n/m

alfu

nctio

n

Mai

nten

ance

Chec

kcy

cle

Mai

nten

ance

re

ques

t

Lim

it va

lue



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Bus variant

Figure 28 Bus variant

VCME 1

Plug

Onsite connection cable between MCU, connection boxes and VCME (→ p. 37, §3.3.1)

Socket

VCME 8

VCME 2 to 7

Connection box 1 to 8

MCU processor board

Whi

teYe

llow

Gre

enBr

own

Ope

ratio

n/m

alfu

nctio

n

Mai

nten

ance

Chec

kcy

cle

Mai

nten

ance

re

ques

t

Lim

it va

lue

Plug

Socket

MaintenanceCheck cycle

Whi

teBr

own

Gre

enYe

llow

Whi

teYe

llow

Gre

enBr

own

Plug assignment (View on pin side)

RS485 B 3

RS485 A4

5

6-24 V

2

7

1+24 V



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Fitting and connecting optional Interface and I/O modules

Plug interface modules and module carriers for I/O modules onto the hat rail in the MCU (→p. 38, Fig. 24) and connect to the associated connection on the processor board with thecable with plug-in connector (→ p. 39, Fig. 25). Then plug the I/O module on the modulecarrier.

Connect I/O modules using the terminals on the module carrier (→ Fig. 29, Fig. 30, Fig. 31),the Profibus module using the terminals on the module and the Ethernet module via onsitenetwork cable.

● Terminal assignment, AO module

Figure 29 Terminal assignment, analog output module

● Terminal assignment, AI module

Figure 30 Terminal assignment, analog input module

● Terminal assignment, DO module power relay (2 changeover contacts)

Figure 31 Terminal assignment, digital output module power relay

● Terminal assignment, DO module signal relay (4 NO contacts)

Figure 32 Terminal assignment, digital output module signal relay (4 NO contacts)

+

1 AO

1

+ 2

AO

2

Shi

eld

11 12 13 14

21 22 23 24

+ -

Analog output module Module carrier

AO 1

+ -AO 2

+

1 AI1 11 12 13 14

21 22 23 24

+ 2

AI2

Shi

eld

+ -AI 2

+ -AI 1

Analog input module Module carrier

n.c. com. com. n.c.

D

igita

l

Out

ut

1 2 DO

1D

O2

Pow

er

R

ela

y

11 12 13 14

21 22 23 24

DO1 DO2n.o. com. com. n.o.

Digital output module Module carrier

n.o. com. com. n.o.

DO1 DO3

Digital output module module carrier DO2 DO4n.o. com. com. n.o.



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3.3.3 Connecting the control unit in 19” rack

Figure 33 MCU connections in 19" variant

Terminals for power supply 90 - 250 VAC Terminals for customer cables

Function Connection Terminal No.Output relay 1 (operation/malfunction) com 1

n.c.1) 2n.o.2) 3

Output relay 2 (maintenance) com 4n.c.1) 5n.o.2) 6

Output relay 3 (check cycle) com 7n.c.1) 8n.o.2) 9

Output relay 4 (maintenance request) com 10n.c.1) 11n.o.2) 12

Output relay 5 (limit value) com 13n.c.1) 14n.o.2) 15

Digital input d in 1 16d in 2 17gnd 18

d in 3 19d in 4 20gnd 21

Analog output + 22- 23

gnd 24Analog input AI 1 25

gnd 26AI 2 27gnd 28



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1): Closed in currentless condition (normal closed)2): Open in currentless condition (normal open)

Installing and connecting optional I/O modules

Plug optional analog and digital modules without gaps in the plug-in slots on the modulecarrier starting with plug-in slot 1 in consecutive sequence AO → AI → DO → DI. If singlemodule types are not available, the next one follows according to the sequence mentioned.

Figure 34 Plug-in slots for optional modules

Connection is made on terminals 101-180 of the backplane.

Connections for measuring unit +24 31 (36)-24 32 (37)

RS485 A 33 (38)RS485 B 34 (39)

scr. 35 (40)Input voltage supply 24V DC 24 V 41

gnd 42Output voltage supply 24V DC 24 V 43

gnd 44Input 30 V galv. separated + 45

- 46RS232/485 tx/A 51

rx/B 52gnd 53

Interface 1 A 71B 72

gnd 73+Us 74-Us 75gnd 76

imp+ 77imp- 78res 1 79res 2 80

Function Connection Terminal No.

SICKMULTI CONTROL UNITPOWER

FAILURE

MAINTENANCEREQUEST

INTERFACE-MODULEI/O-MODULE

POWER

ERROR

TxD RxD

Plug-in slots for optional I/O modules Plug-in slot for interface module option

8 7 6 5 4 3 2 1Plug-in slot



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I/O module connection is shown in the following using plug-in slot 1 as an example. I/Omodules are connected to plug-in slots 2-8 in the same manner.

● Analog module connection

Figure 35 Analog module connection to plug-in slot 1 (terminals 101-110

● Digital module connection

Figure 36 Digital module connection to plug-in slot 1 (terminals 101-110)

101 a

102 b

103 c

104 d

105 a

106 b

107 c

108 d

109 -gnd

110 scr

101 a

102 b

103 c

104 d

105 a

106 b

107 c

108 d

109 -gnd

110 scr

+

+

+

+

-

-

-

-

AO (2x) AI (2x)

101 a

102 b

103 c

104 d

105 a

106 b

107 c

108 d

109 -gnd

110 scr

+

+

+

+

-

-

-

-

101 a

102 b

103 c

104 d

105 a

106 b

107 c

108 d

109 -gnd

110 scr

101 a

102 b

103 c

104 d

105 a

106 b

107 c

108 d

109 -gnd

110 scr

Signal relays (4x) Power relays (2x) DI (4x)



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3.3.4 Connecting the measuring unit(s) Connect the connection cable to the MCU.

Connect the air intake and exhaust air hoses.

Figure 37 Connections on underside of the measuring unit

Connecting the measuring unit with optional power supply unit 24 V DC 75 W to mains voltage

Connect the plug-in connector belonging to the scope of delivery for this version as shownin the following Figure.

Figure 38 Connecting the measuring unit with optional power supply unit 24 V DC 75 W to mains voltage

1 2 3 4 5 6

*: Replaced by sockets when the temperature measurement option is installed

1 Air outlet connection2 Plug for separate power supply for the

measuring unit3 Plug for connecting cable to the MCU4 Dummy plug *5 Dummy plug for additional cable6 Air inlet connection

WARNING:The cable may only be connected to the plug-in connector by an authorized expert!

2 ClosedClosed

Open Open A

A

A -A

1L

N3

PE

6

3

4

5

1

1 Plug-in connector (scope of delivery)2 Onsite cable 3 x 1.5 mm² (e.g. NYMHY3x 1.5 mm²)3 Measuring unit4 Plug-in connector (scope of delivery)5 Onsite cable 6 Onsite mains connection



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Connecting the temperature measurement option

Connect the plug connected to the measuring line to the associated socket on the measuring unit

NOTICE:The assignment of the temperature sensor(s) to the connection(s) on the measuring unit according to the identification must be adhered to absolutely because the electronics and temperature sensor are adjusted to each other (adhere to the equipment-specific assignment when several measuring units with this option are used!)



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3.3.5 Terminating the VCME - MCU connectionThe RS485 connection between VCME and MCU must be terminated with resistors at thestart and end. These are inserted as jumpers on the pins marked "term" on the processorboards of VCME and MCU.

Disconnect MCU and VCME from power supply for checking (and correction if necessary).

Figure 39 Bus termination

MCU

MCU

VCME 1 VCME 2 VCME 8

VCME 1 VCME 2 VCME 8

MCU at bus start

MCU in bus middle

Processor board Jumper

Processor board

Jumper

Processor board

Jumper

AB x = connection box option x



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3.3.6 Bus addressingThe bus addresses required for bus systems (several measuring units on one MCU) can beassigned per hardware or software. Hardware addressing is read in at the start ofSOPAS ET and has a higher priority than software addressing.

Bus address and sensor number in the MCU () are always identical.

Hardware addressing

As standard, the addresses are assigned by setting jumpers on the processor board in themeasuring unit (4 for hexadecimal addressing of addresses 1 to 8; → Fig. 40).

The address assigned to a measuring unit is shown on a label on the unit door.

Figure 40 Measuring unit addressing per hardware

NOTICE:The measuring units must have different addresses. Identical addresses of several units causes the communication with the MCU to abort!

Jumper not set

Jumper set

Processor board

Address Jumper Address Jumper Address Jumper Address Jumper

1 3 5 7

2 4 6 8



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Software addressing

Alternatively, addressing can also be assigned in SOPAS ET (→ Fig. 41). To do so, connectthe measuring system to SOPAS ET, select the ”VICOTEC450” device file and set themeasuring system to ”Maintenance” mode.

Figure 41 ”Parameter / Busaddress“ directory

NOTICE:No jumpers may be set (→ p. 49, Fig. 40).

The default value for the bus address is always 1. Assign higher addresses to units already connected before connecting further measuring units to the bus.


Startup and Configuring

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VICOTEC450

4 Startup and Configuring

Basics

Customizing the configuration

Configuring optional modules

Operating/configuring via the LC-Display option



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4 . 1 Basics

4.1.1 General informationPrerequisite is that assembly and installation have been completed as described inSection 3.

The VICOTEC450 is delivered with default values set at the factory so that start-up primarilyinvolves checking cable and hose connections (visual control) and switching on the mainsvoltage. Zero point adjustment or calibration of the measuring system are not required.

The customer only needs to change parameters when the default values need to bemodified (e.g. to set a limit value for smoke alarm). SOPAS ET is delivered with the deviceand can be used in such cases. The menu structure simplifies changing settings. Furtherfunctions are also available (e.g. data storage, graphic displays).

4.1.2 Installing the SOPAS ET operating and parameter program

Requirements

● Laptop/PC with:

– Processor: Pentium III (or comparable type)

– USB interface (alternative - RS232 via adapter)

– Working memory (RAM): At least 256 MB

– Operating system: MS Windows ME/2000/XP/Vista (not Windows 95/98/NT)

● USB interface cable to connect the Laptop/PC to the measuring system (MCU).

● The operating and parameter program as well as the USB driver (scope of delivery) must be installed on the Laptop/PC.

● The voltage supply must be switched on.

Installing SOPAS ET

Insert the delivered CD in the PC drive, select the language, select "Software" and followthe instructions.

Installing the USB driver

A special software driver is required for communication between SOPAS ET and themeasuring system via the USB interface. Connect the MCU to the supply voltage and to thePC via USB cable to install the driver on the Laptop/PC. A message appears on the displaythat new hardware has been detected. Then insert the delivered CD in the PC drive andfollow the installation instructions (→ p. 53, Fig. 42). The driver can also be installed by usingthe hardware installation program of the Windows Control Panel.

Administrator access rights are required for installation.

NOTICE:SOPAS ET with version 02.22 (or higher) must be used for measuring units with firmware version as from 03.00.00 (otherwise communication is not possible).

Start the file "setup.exe" should the start screen not appear.

The USB driver creates a new COM port that is then used to connect SOPAS ET with the device (→ p. 57, §4.1.3.2).



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Figure 42 Installing the USB driver



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4.1.3 Connecting the device Connect the USB cable to the MCU control unit (→ p. 39, Fig. 25) and Laptop/PC.

Start the program from the "SICK\SOPAS" start menu.

The start dialog appears on the screen (can be suppressed for further program use).

Figure 43 Start dialog

The following Start menu appears after confirmation with "OK".

Figure 44 Start menu

If required, select the desired language in the "Tools / Language" menu (→ p. 55, Fig. 45→ p. 55, Fig. 45), confirm with "OK", and restart the program.

Project selection

Deactivating the Start dialog



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Figure 45 Changing the language setting

4.1.3.1 Configuring the interface

COM Port

Click "Network Configuration" in the start menu (→ p. 54, Fig. 44) and select "Standard Protocol".

Select the COM port in the "Select COM Ports" group that appears after connection of MCU and Laptop/PC, click the "Advanced..." button and configure in accordance with Fig. 46 (settings only required during the first connection to the measuring system).

Figure 46 COM port selection and configuration



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Ethernet

Click "Network Configuration" in the start menu (→ p. 54, Fig. 44) and select "Internet Proto-col (IP)".

Click "Add ", enter the IP address and confirm with "OK".

Figure 47 Ethernet interface selection (example settings)

Click "Advanced..." and configure the interface in accordance with Fig. 48.

Figure 48 Configuring the Ethernet interface

The Ethernet interface module (→ p. 115, §7.4.2) must be installed in the MCU (→ p. 38, §3.3.2) and configured (→ p. 80, §4.3.2) to connect to the measuring system via Ethernet.



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4.1.3.2 Connecting using the "Network Scan Assistant" directory

Click "Network Scan" in the "Network Scan Assistant" directory.

Figure 49 Searching for connected devices

Confirm search for connected devices with "OK".

The following message appears when no device is found (troubleshooting, seeService Manual):

Connection via COM port

Connection via Ethernet

Problems with Ethernet connections can be caused by incorrect addressing → contact system administrator.



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4.1.3.3 Connecting using the "Connection Wizard" menu (valid as from SOPAS ET Version 02.32)

Select menu "Communication / Connection Wizard" and activate "Show all connected devices".

Figure 50 "Communication / Connection Wizard" menu

Click "Next >" and select the interface ("Standard Protocol" for connection via COM port, "Internet Protocol (IP)" for connection via Ethernet).

Figure 51 Selecting the interface

Check the interface configuration for settings in accordance with p.57, §4.1.3.2 and change accordingly if necessary.

Click "Next >".



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Figure 52 Searching for connected devices

The following message appears when no device is found (troubleshooting, seeService Manual):


Connection via Ethernet



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4.1.3.4 Selecting the device


Select the required device file in the "Network Scan Assistant / Detected devices" registerand move it to the "Project Tree" window (drag-and-drop per mouse or click "Add").

Figure 53 Selecting the device file

Connection via "Connection Wizard" menu

Activate the checkbox of the required device file in the "Connection Wizard / Founddevices" (→ p. 59, Fig. 52) and click "Next >". This transfers the device file to the "ProjectTree" window.

Figure 54 Transferring the device file



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4.1.4 Information on using the program

Password

Certain device functions are first accessible after a password has been entered (→ Fig. 55).Access rights are assigned in 3 levels:

*): Depends on the program version

The level 1 password is contained in the Annex.

Figure 55 Entering the password

User level Access to

0 Operator Display measured values and system states

1 Authorized Operator(Authorized Client) *

Display, inquiries as well as start-up or adjustment to customer-specific demands and diagnosis of necessary parameters

2 Service Display, inquiries as well as all parameters required for service tasks (e.g. diagnosis and clearance of possible malfunctions)



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4.1.5 Online HelpIndividual menus and setting options are described in detail in the Online Help and aretherefore not described further here.

Figure 56 Online Help

Installed program version



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4 . 2 Customizing the configuration

Factory settings

Connect the measuring system to SOPAS ET and move the required device file to the"Project Tree" window (→ p. 54, §4.1.3) to set or change parameters. Then enter the level 1password (→ p. 61, §4.1.4), and set the measuring system to "Maintenance" mode (open the"Maintenance/Maintenance" directory, activate the "Maintenance on/off" checkbox, andpress "Set State".

Use device file "MCU" to configure.

Figure 57 Setting "Maintenance" mode

Parameter Value

Analog output setting (AO)

Live zero (LZ) 4 mA

Upper measuring range value 20 mA

Current during maintenance 0.5 mA

Current by malfunction No output on AO

Output on standard AO

Measured variable k value

Value for LZ 0 /km

Value for FS 15 /km

Check cycle Every 24 h; no output of check values on stan-dard analog output

Response time 60 s for all measured variables

Coefficients set (only for dust concentration) 0.00 / 1.00 / 0.00



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4.2.1 Assigning the sensorsThe MCU must be assigned to the connected measuring unit. A malfunction is reported incase of a mismatch. Assignment must be made after installation when the setting is notpossible at the factory (e.g. when several devices are delivered at the same time or whenthe MCU is swapped later). The following steps are then necessary:

Select the "MCU" device file and open the "Configuration / Application selection“ direc-tory.

Click "Reset MCU" when the type shown in the "Variant" window ("Application selection" group) is correct ("Universal" for VICOTEC450).

Figure 58 Assigning the sensor

4.2.2 Activating connected measuring unitsAll measuring units connected to the MCU must be activated for correct communication bychecking them in the "Connected sensors" group in the "Configuration / SystemConfiguration" directory (→ p. 65, Fig. 59) (correct when necessary).

The measuring unit must be connected to the MCU.



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Figure 59 "Configuration / System Configuration" directory (example for settings)

4.2.3 Assigning the measuring system to the installation locationMeasuring unit and MCU can be assigned explicitly to the respective measuring location.

Select "Configuration / Application Selection“ directory (→ p. 64, Fig. 58) for the MCU.

Move the "Vicotec450" device file into the "Project tree" window and select the "Over-view" directory for the measuring unit.

Enter the desired name in the "Location" window.

Figure 60 "Overview" directory



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4.2.4 Defining the check cycle To set/change the interval time, control value output on the analog output and the starting

timepoint for the automatic check cycle, move the "MCU" device file into the "Project tree"window and select the "Adjustment / Function Check - Automatic" directory.

Figure 61 "Adjustment / Function Check - Automatic" directory (example for settings)

Default values → p. 63, §4.2

Field Parameter Remark

Function check out-put duration

Value in seconds Output duration of control values

Output duration of function control value at AO

Inactive Control values are generally not output on the analog out-put.

Active Control values can be output on the respective analog out-put depending on this setting (→ p. 68, Fig. 63).

Function check inter-val

Time between two check cycles

→ p. 15, §2.1.4(recommended value 24 h)

Function Check Start Time

Hours Defines a start timepoint in hours, minutes and seconds

Minutes

Seconds



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4.2.5 Configuring the analog output

Basic settings

Enter the current to be output on the analog output in the "Maintenance" or "Malfunction"state in the "Configuration / I/O Configuration / Analog Output / Analog Outputs - GeneralOverview" directory.

Figure 62 "Overview" submenu (example for settings)

Configuring

The "Configuration / I/O Configuration / Analog Output / AO Parameters" directory servesto assign the signal source (measuring signal of a measuring unit) to the standard analogoutput (AO), and to define the values for Live Zero and measuring range.


Error Current Value < Live Zero (LZ) or > 20 mA

mA value to be output in "Malfunction" state (error case) (size depends on con-nected evaluation system).

Output error current yes The error current is output.

no The error current is not output.

Maintenance current Value if possible ≠ Live Zero

mA value to be output during "Maintenance" mode

Current in mainte-nance

User value A value to be defined is output during "Maintenance"

Last measured value The value measured last is output during "Maintenance"

Measured value out-put

The current measured value is output during "Maintenance".



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Figure 63 "AO Parameters" submenu (example for settings)

1): Assignment is made at the factory in the predefined sequence. The next sequentialmeasured variable moves up one position when an option (*) has not been ordered.Assignment is made by SICK Service when options are added later.

2): Only important for special applications


Source sensor Sensor 1 to 8 Measuring unit for which the output signal is to be assigned to the analog out-put.

Source value 1) Value 1 Scattered light intensity

Value 2 Inlet temperature [°C]

Value 3 Heater temperature [°C]

Value 4 External temperature 1 [°C] *


Value 6 Dust concentration [mg/m³] * 2)

Value 7 k value [/km]

Value 8 Visibility [m]

Live Zero Zero point (0, 2 or 4 mA) Select 2 or 4 mA to ensure being able to differentiate between measured value and switched off device or interrupted current loop.

Range low Lower measuring range limit Physical value at live zero

Range high Upper measuring range limit Physical value at 20 mA

Output check cycle results on the AO

Inactive Control values (→ p. 15, §2.1.4) are not output on the analog output .

Active Control values are output on the analog output (the "Output control values at AO" checkbox in the "Adjustment / Function Check - Automatic" directory must be activated).

Write absolute value

Inactive Positive and negative measured values are differentiated.

Active The amount of the measured value is output.



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4.2.6 Configuring the analog inputsThe "Configuration / I/O Configuration / Analog input / General Configuration" directoryserves to assign the standard analog inputs (groups "Parameter analog input 1" and"Parameter analog input 2") to measured values for possible scaling, and to define therespective measurement range.

Figure 64 "Configuration / I/O Configuration / Analog input / General Configuration" directory (example for settings)

NOTICE:Calibration coefficients CC2, CC1 and CC0 are predefined at the factory and may only be changed by SICK Service.


Aim value in the MCU measurement block

Measured value 1 to 8 Variable to be assigned to the selected analog input

Range low Lower measuring range limit Physical value at live zero

Range high Upper measuring range limit Physical value at maximum current

Live Zero Zero point value > 0 mA) Specification of the mA value for measurement range start

Indicate NAMUR error Inactive No error is reported for underflow or overflow of the set current range (LZ to 20 mA).

Active An error is reported for underflow or overflow of the set current range (LZ to 20 mA).



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4.2.7 Configuring the limit value relaySelect the "Configuration / Limit Value Switches" directory for configuring.

Figure 65 ”Configuration / Limit Values Switches” directory

1): Assignment is made at the factory in the predefined sequence. The next sequentialmeasured variable moves up one position when an option (*) has not been ordered.Assignment is made by SICK Service when options are added later.



Source sensor Sensor 1 to 8 Sensor for which a limit value is to be assigned to the output signal.

Source value 1) Value 1 Scattered light intensity





Value 6 Dust concentration [mg/m³] * 2)



Limit value Value The limit value relay switches when the entered value is overflown or underflown.

Switch at Over Limit Specification of the switching direction

Under Limit

Hysteresistype

Percent Assignment of the value entered in the "Hysteresis Type" field as relative or absolute value of the defined limit valueAbsolute

Hysteresis Value Defines a tolerance for resetting the limit value relay

Aim bit at MCU status Relay 5 Aim bit = special memory in the MCU for monitoring limit values



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4.2.8 Calibrating for dust concentration measurement

For exact dust concentration measurement, the relation between the primary measuredvariable scattered light intensity and the actual dust concentration at the measuringlocation must be established. To do this, the dust concentration must be determinedbased on a gravimetric comparison measurement in accordance with EN 13284-1 orcomparable regulations and set in relation to the scattered light values measured at thesame time by the measuring system.

Steps to be taken

Select the "Configuration / I/O Configuration / Analog Output / AO Parameters" direc-tory (→ p. 68, Fig. 63) and assign the "Scattered light intensity" measured variable to the analog output.

Estimate the measuring range required for the dust concentration in operational state and enter the lower and upper measuring range limits

Deactivate "Maintenance" mode.

Carry out the gravimetric comparison measurement in accordance with EN 13284-1,.

Determine regression coefficients from the mA values of the analog output for "Scat-tered light intensity" and the dust concentrations act. measured gravimetrically.

c: Dust concentration in mg/m³

K2, K1, K0: Regression coefficients of the function c = f (Iout )

Iout: Current output value in mA

SI: Measured scattered light intensity

LZ: Live Zero

MBE: Defined upper range limit (value entered for 20 mA; normally 2.5 x fixed limit value)

Enter the calibration coefficients

There are two options:

– Direct input of K2, K1, K0 in a measured value computer.

Measuring the dust concentration is only important for special applications.

NOTICE:The steps described here serve to avoid input errors. Carrying out comparison measurements demands special knowledge that cannot be described in detail here.

NOTICE:In this case, the regression coefficients set in the measuring unit and the measuring range set in the MCU may not be changed anymore. The dust concentration is displayed in mg/m³ on the LC-Display as an uncali-brated value.

c K2 Iout2⋅ K1 Iout⋅ K0+ += (1)

Iout LZ SI 20mA LZ–MBE

-----------------------------⋅+= (2)



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– Using the regression function of the measuring system (measured value computer not necessary).

In this case, the correlation to the scattered light intensity has to be determined. To do this, calculate the regression coefficients cc2, cc1, cc0 to be entered in the measuring system from K2, K1, K0.

By using (2) in (1), the result is as follows:

Using (3), the result is as follows:

Now enter the determined regression coefficients cc2, cc1 and cc0 in the "Parameter / Capt_CoeffReg_Conc" directory. To do this, select the "Vicotec450" device file, set the measuring unit to "Maintenance" mode and enter the level 1 password.

Figure 66 "Parameter / Capt_CoeffReg_Conc" directory

Switch the measuring unit back to "Measure" mode after entering the coefficients.

c cc2 SI2⋅ cc1 SI⋅ cc0+ += (3)

c K2 LZ SI 20mA LZ–MBE

-----------------------------⋅+ 2

K1 LZ SI 20mA LZ–MBE

-----------------------------⋅+ K0+⋅+⋅=

cc1 2 K2 LZ K1+⋅ ⋅( ) 20mA LZ–MBE

----------------------------- ⋅=

cc0 K2 LZ2⋅ K1 LZ⋅ K0+ +=

cc2 K2 20mA LZ–MBE

----------------------------- ⋅

2=

This method allows changing the parameters for the selected measuring range as desired.



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4.2.9 Setting the response timeSelect the "Configuration / Value Damping" directory to set the response time.

Figure 67 "Configuration / Value Damping" directory (display for one connected measuring unit)

4.2.10 Flow measurementThe flow rate is adjusted at the factory so that no further work is required onsite.


Damping time for Sensor 1

Value in s Response time for the selected measured variable ( → p. 15, §2.1.3)(recommended value 60 s)

If more than one measuring unit is connected, a separate input window exists for each measuring unit to set the individual response time.

Changes may be made only by trained personnel (user level "Service" is required, see Service Manual).



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4.2.11 Data backupAll parameters relevant for recording, processing and input/output of measured values aswell as current measured values can be saved and printed. This allows easy reentering ofset device parameters as needed (e.g. after a firmware update) as well as the registrationof device data or device states for diagnostic purposes.

The following options are available.

● Saving as a project (particularly advantageous for diagnosis and troubleshooting)

This allows saving not only device parameters but also data logs.

● Saving as a device file

Stored parameters can be processed without the device attached and transferred into the device again later.

● Saving as a protocol (MCU)

Device data and parameters are recorded in the Parameter protocol. A Diagnosis protocol can be created for analysis of the device function and detection of possible malfunctions.

Saving as a project

It is recommended to store a "project" when connections are frequent. Only the "project"needs to be opened for renewed connection. All data stored previously are transmittedautomatically to SOPAS ET.

To save, select the "Project / Export Device" menu and then define the target directory andfile name. The name of the file to be stored can be chosen freely. It is useful to specify aname with a reference to the sampling point involved (name of the company, equipmentname).

Figure 68 "Project / Save Project" menu

See the Service Manual for a description.



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4.2.12 Starting normal measuring operationSet the measuring system to "Measurement" mode after entering/modifying parameters.To do this, switch to the "Maintenance / Maintenance" directory, deactivate the"Maintenance on/off" checkbox and click "Set State" (→ Fig. 69). Standard start-up is nowcompleted.

Figure 69 Setting the operational state



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4 . 3 Configuring optional modules

4.3.1 Configuring analog and digital output modulesTo do this, the modules installed in the MCU must be activated. Move the "MCU" device fileinto the "Project tree" window, select the ”Configuration / System Configuration” directoryand check whether the number of outputs set in the ”Number of external I/O” groupcorresponds to the existing outputs (correct when necessary).

Figure 70 ”Configuration / System Configuration” directory (example for settings)

4.3.1.1 Optional analog outputs

Configure in accordance with → p. 67, §4.2.5 (→ p. 68, Fig. 63).

The basic settings ("Analog Outputs - General Overview" subdirectory; → p. 67, Fig. 62) applyto all available analog outputs in the same manner.



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4.3.1.2 Optional digital outputs

Select the ”Configuration / I/O Configuration / Digital Output / Digital outputs” directory forconfiguration.

Figure 71 ”Configuration / I/O Configuration / Digital Output / Digital outputs” directory


inverted Inactive Specification of the switching direction

Active

Source bit Bit 0 Malfunction

Bit 1 Maintenance

Bit 2 Maintenance request

Bit 3 Function check

Bit 7 Operation (no malfunction)

Bit 16 to 31 Aim bit of the limit value switch (→ p. 79, Fig. 73)

Source sensor Selection of the component:- Sensor 1 to 8 when the device status is to be output- MCU when limit values are to be reported



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Checking settings

The current status of each relay is shown in the "Diagnosis / I/O / Digital Outputs"directory.

Figure 72 "Diagnosis / I/O / Digital Outputs" directory

To check whether relays switch as intended, measured values which exceed the configuredlimits must be created.

In addition, a continuity tester can be connected to the respective relay output for anexternal check.



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4.3.1.3 Assigning and configuring limit value switches to optional digital outputs

Select the ”Configuration / Limit Values Switches” directory” for assigning. Configure inaccordance with → p. 70, §4.2.7.

Figure 73 ”Configuration / Limit Values Switches” directory



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4.3.2 Configuring optional Interface modules

4.3.2.1 General information

The following steps are necessary to select and set the optionally available Interfacemodules Profibus DP and Ethernet:

Select the "MCU" device file, set the measuring system to "Maintenance" mode and enter the level 1 password (→ p. 61, §4.1.4).

Switch to the "Configuration / System Configuration" directory.

The Interface module installed is shown as "Interface Module".

Configure the Interface module as required.

Figure 74 "Configuration / System Configuration" directory

GSD file and measured value assignment are available for the Profibus DP module on request.



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4.3.2.2 Configuring the Ethernet module

Assigning a new IP address to the Ethernet modules

An IP address specified by the customer is entered at the factory when the address isavailable when the device is ordered. Otherwise standard address 192.168.0.10 isentered.

The following steps are necessary to make a change:

Switch to the „Parameter / IO Configuration / Interface Module“ directory.

Enter the desired network configuration in the "Ethernet Interface Configuration“ group and click "Reset module" under "Expansion module information".

Figure 75 "Configuration / IO Configuration / Interface Module" directory

NOTICE:The risk of undesired access to the measuring system is inherent when communicating via Ethernet. Operate the measuring system only behind suitable protection (e.g.

Firewall).

new address



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Assigning the new IP address to SOPAS ET

Select the "Network Scan Assistant" register and click "Network Configuration".

Select the "Internet Protocol (IP)" directory, set the "Enable IP Communication" entry field to active and click "Add".

Enter the new IP address set in the "Configuration / IO Configuration /Interface Module" directory and confirm with "OK".

Figure 76 Entering the IP address (example)

Click "Advanced..." in the "Internet Protocol (IP)“ directory.

Select port address "2111" and confirm with "OK" (all other settings are factory settings in accordance with Fig. 77).



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Figure 77 Specifying the TCP port

Select the "Network Scan Assistant" register, click "Network Scan" and check whether the set address is displayed.

Figure 78 Network scanning

Activate only the required TCP port. To use a TCP port other than 2111 or 2112, activate the "Custom”

checkbox and enter the port number in the adjacent field.

NOTICE:During communication via Ethernet, disturbances in data transfers can arise which are not caused by the measuring system. If measured values are transferred exclusively via Ethernet and used to

control processes, disturbances in plant operation are possible for which the VICOTEC450 manufacturer is not responsible.

Increasing the value in field "Scan timeout" from 500 ms to 3000 ms can minimize communication problems.



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4 . 4 Operating/configuring via the LC-Display option

4.4.1 General information on useThe display and operating interface of the LC-Display contains the functional elementsshown in Fig. 79.

Figure 79 LC-Display functional elements

Button functions

The function shown depends on the Menu currently selected. Only the function shown inthe button is available.

Status bar

Number of the connected sensor

Measured value bar

Status LED

Current button function

Control buttons

Button Function

Diag Display diagnostic information (warnings and errors during a start using the Main menu, sensor information during a start using the Diagnostics menu; → p. 85, Fig. 80)

Back Switch to higher level menu

Arrow Scroll up

Arrow Scroll down

Enter Execution of the action selected with an arrow button (switch to a submenu, confirm parameter selected during configuration)

Start Start an action

Save Store a changed parameter

Meas ● Toggle between display of measured values in a bar (graphics display) or in text formWhen connecting several measuring units to one MCU, the measured values of the individual measuring units are shown in succession.

● Display the contrast setting (press the button at least 2.5 s)



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4.4.2 Menu structure

Figure 80 LC-Display menu structure

4.4.3 Configuring

4.4.3.1 MCU

Analog outputs / inputs

Set the MCU to "Maintenance" mode and select the "I/O Parameter" submenu.

Select the desired parameter and enter the default password "1234" using the "^" (scrolls from 0 to 9) and/or "→" (moves the cursor to the right) buttons.

Select the desired value using the "^" and/or "→" buttons and write it to the device with "Save" (confirm 2x).

1): as in the operating mode2): → p. 85, §4.4.3.13): → p. 87, §4.4.3.2

1)

2)

}

1)}

3)



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Figure 81 Menu structure for configuring analog outputs / inputs and setting the MCU variant

Setting the MCU variant

The following steps are required to set the MCU for the VICOTEC450 measuring unit to beconnected (→ p. 64, §4.2.1), :

Set the MCU to "Maintenance" mode, select the "MCU Variant" submenu, and select the type "Universal (Bus)".

Enter the default password and store the type with "Save" (confirm 2x).

The other selection options have no significance here.



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4.4.3.2 Measuring unit (when setting to measure the dust concentration)

The following steps are required to enter the regression coefficients:

Set the measuring unit to "Maintenance" and select the "Parameter" submenu.

Choose the parameter to be entered and enter the default password "1234".

Set the calculated coefficients (→ p. 71, §4.2.8) using the "^" and/or "→" buttons and write to the device with "Save" (confirm 2x).

Figure 82 Entering the regression coefficients

Back Enter

1 cc22 cc13 cc0

Parameter

/ /paramsensor/1

Back Save

Back Save

Back Save

Back Save

000.000

000.000

-01.130.

-06.780

Parameter

Parameter

Parameter

Parameter

Back Save

Back Save

Password XXXX

Password XXXX

Parameter

Parameter

Back Save Back Save

001.000 000.560.

Parameter Parameter

Back Save

Password XXXX

Parameter



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4.4.4 Using SOPAS ET to modify display settingsTo modify the factory settings, select device file "MCU" in the "Project tree“ window, enterthe level 1 password and select the "Configuration/Display Settings“ directory.

Figure 83 "Configuration/Display Settings“ directory

Field Field Significance

Common Display Settings

Display language Language version shown on the LC-Display

Display Unit System Unit of measure system used in displays

Overview Screen Settings

Bar 1 to 8 Sensor address for the respective measured value bar in the graphic display

Value Measured value index for the respective measured value bar

Use AO scaling When activated, the measured value bar is scaled to the associated analog output. If this selection box is not activated, define the limit values separately

Range low Values for separate scaling of the measured value bar independent of the analog out-put Range high



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Measured value assignment

1): The next sequential measured variable moves up one position when an option has notbeen ordered. Assignment is made by SICK Service when options are added later.


MCU measured value

Measuring unit measured value

Value 1 Scattered light intensity



Value 4 External Temperature 1 [°C] 1)

Value 5 External Temperature 2 [°C] 1)

Value 6 Dust concentration [mg/m³] 1) 2)





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Maintenance

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VICOTEC450

5 Maintenance

General information

Maintaining the measuring unit

Putting out of operation


Maintenance

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5 . 1 General informationThe maintenance work to be carried out consists of:

● Checking and cleaning the optical boundary surfaces

● Examining installed air intake and exhaust air hoses

● Checking the door of the measuring unit

● Exchanging the air filter of the measuring unit.

Switch the VICOTEC450 to "Maintenance" mode before starting any maintenance work (→p. 63, §4.2).

Switch back to measuring operation when the work has been completed → p. 75, §4.2.12 oropen the contact on Dig In 2).

Maintenance intervals

The tunnel operator is responsible for defining the maintenance intervals. The intervalsdepend on the specific operating parameters and ambient conditions. Maintenanceintervals are normally 1 year. Longer maintenance intervals are possible for favorableconditions.

The activities required and their completion must be documented by the operator in aMaintenance Manual.

Maintenance contract

Regular maintenance activities can be carried out by the tunnel operator. These activitiesmust only be carried out by qualified persons according to Section 1. If requested, allmaintenance activities can also be performed by SICK Service or an authorized Servicepartner.

Auxiliary means required

● Brush, cleaning cloth, cotton swabs

● Water

● Replacement air filter, preliminary filter (for suction)

WARNING:All activities must be carried out in line with the relevant safety regulations and instructions (→ p. 9, §1.3).

● "Maintenance" mode can also be set by connecting an external maintenance switch to the terminals for Dig In2 (17, 18) in the MCU (→ p. 46, §3.3.4) or using the buttons on the LC-Display on the MCU (→ p. 85, §4.4.2) if this option is available.

● No automatic check cycle is carried out during "Maintenance".● The value set for "Maintenance" is output on the analog output (→ p. 67,

§4.2.5). This also applies when a malfunction exists (signalized on the relay output).

● "Maintenance" mode is reset when there is a voltage failure. In this case, the measuring system switches automatically to "Measurement" after the operating voltage is switched on again.


Maintenance

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5 . 2 Maintaining the measuring unit

5.2.1 Inspection work Check air intake and exhaust air lines.

Check the lines regularly for tight connection and any possible deposits inside. If neces-sary, disconnect the lines from the connections and flush with water.

Check the light trap for contamination.

Check the laser beam for free passage through the aperture.

Check the fan for audible running noises.

Check the seal on the door of the measuring unit for intactness.

5.2.2 Cleaning the optical boundary surfaces of laser module and receiverOnly clean the optical boundary surfaces when deposits are visible or before thecontamination value reaches the 30% warning limit (50% for malfunction).

Activities

Open the measuring unit door.

Clean the optics carefully with cleaning sticks and, if necessary, the light trap as well.

Close the door again tightly (tighten the lock screws firmly).

Figure 84 Cleaning the optics

NOTICE:Do not damage any device parts during maintenance work.

NOTICE:Measuring results can be incorrect when the door is not tight..

1 2 3 4

1 Sender lens 3 Receiver optics2 Aperture 4 Light trap


Maintenance

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5.2.3 Cleaning the coarse filter in the air inlet Disconnect the measuring unit from the mains (disconnect the connection cable to

MCU or mains voltage supply).

Open the cover on the air inlet (→ p. 108, Fig. 94, → p. 109, Fig. 96).

Remove the coarse filter and clean it (rinse when necessary), replace with a new filter when necessary (→ p. 116, §7.5).

Put the coarse filter back into the air inlet and close the cover.

Reconnect the mains voltage.

5.2.4 Replacing the air filterReplace the air filter regularly. The interval should be 1 year.

Activities

Disconnect the measuring unit from the mains (disconnect the connection cable to MCU or mains voltage supply)

Open the door of the measuring unit.

Turn the cover of the air filter housing up after loosening the knurled nuts.

Remove the old air filter and insert a new one.

Then refit and tighten the cover.

Close the door again tightly (tighten the lock screws firmly).

Reconnect the mains voltage.

Figure 85 Replacing the air filter

When the fan is switched on, particles can penetrate and contaminate the optics.

1 2 3 1 Knurled nut2 Housing cover3 Air filter


Maintenance

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5 . 3 Putting out of operationPut the VICOTEC450 out of operation during longer tunnel closures or construction workcausing dust in the tunnel.

Activities

Disconnect the connection cable to the control unit.

Pull air intake and exhaust air lines off the connections, secure hose ends to prevent dirt and moisture penetrating the lines.

Dismantle the measuring unit(s).

Disconnect the control unit from mains voltage.

Storage

Store dismantled device parts in a clean, dry location.

Use suitable auxiliary material to protect plug-in connectors of the connection cable against dirt and moisture.

Ensure that no dirt or moisture can enter the air intake and exhaust air lines.

Alternatively, the VICOTEC450 can still be operated in such cases when air intake and exhaust air lines are connected to each other so that neither dust nor humidity can penetrate.

WARNING:● When disassembling, observe the relevant safety regulations and the

safety information in Section 1!● Take suitable protective measures against possible local hazards or

hazards arising from the plant!● Secure switches that must not be switched on for safety reasons with

labels and safeguards to prevent unintentional switching on.


Maintenance

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Malfunctions

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VICOTEC450

6 Malfunctions

General information

Measuring unit

Control unit


Malfunctions

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6 . 1 General information Warning or error messages are output as follows:

● On the MCU, the respective relay is switched on (→ p. 39, Fig. 25).

● "Maintenance requ." or "Failure" is displayed in the status bar of the LC-Display (→ p. 84, §4.4.1). In addition, the respective LED goes on ("MAINTENANCE REQUEST" for warn-ings, "FAILURE" for errors).

After pressing the button "Diag", possible causes are shown as short information in the menu "Diagnosis" after selecting the device ("MCU" or "Vicotec450").

Figure 86 Display on the LC-Display

Detailed information on current device status is provided by the „Monitor/System state -details" (measuring unit) or "Diagnosis/Errors/Warnings" (MCU) directories.. Connect themeasuring system to SOPAS ET and start the device file "Vicotec450" or "MCU" (→ p. 54,§4.1.3 and → p. 61, §4.1.4) to display the relevant information.

The significance of the individual messages is described in more detail in a separatewindow after moving the cursor to the respective display. Clicking on the display shows ashort description of possible causes and corrections under "Help" (→ p. 99, Fig. 87, → p. 101,Fig. 89).

Warning messages are output when internal limits for individual device functions/components are reached or exceeded which can then lead to erroneous measured valuesor an imminent failure of the measuring system.

Diagnosis I/O Diagnosis

Diagnosis

/diag /i/o/status

/sensor/status

Back Enter Back Enter

Back Enter

Menu Diag

(1)ROV 2000 0.0 m 1000

0.0 /km 1000

(1)K-Fact 0.036

Display of current warning or malfunction

Warning messages do not imply a malfunction of the measuring system. The current measured value is still output via the analog output.

Refer to the Service Manual for more detailed descriptions of messages and clearance options.


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6 . 2 Measuring unit

6.2.1 Malfunctions

6.2.2 Warning and error messages in SOPAS ET

Figure 87 "Monitor/System state - details" directory

Current warning or error messages, or earlier messages stored in the error memory, can beshown by selecting "actual" or "memory" in the "Selection" window ("Device malfunction"group).→ p. 99, Fig. 87

Symptom Possible cause Action

LEDs are not on ● No supply voltage● Connection cable not connected

correctly or defective● Defective plug-in connector

Check plug-in connector and cable. If the optional power supply unit is

installed, check the fuse and replace if necessary

Contact SICK Service.

Display


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The following malfunctions can possibly be cleared onsite.

6.2.3 Replacing the fuse for the optional power supply unit Open the measuring unit door.

Unscrew the fuse holder, replace the defective fuse and screw the fuse holder in again.

Close the door tightly.

Figure 88 Fuse holder for optional power supply unit

Message Significance Possible cause Action

Contamination Current reception intensity is lower than the allowable limit value (→ p. 106, §7.1)

● Deposits on the optical interfaces

● Unclean purge air

Clean optical surfaces (→ p. 93, §5.2.2). Check purge air filter (→ p. 94, §5.2.3) Contact SICK Service.

Overflow measurement

Reception intensity too high. ● Receiver not in measuring position

● Relay for reception intensity damping defective

Check receiver position Trigger a check cycle and check procedure flow

(→ p. 66, §4.2.4). Contact SICK Service.

Blower failure ● Plug-in connector or cable defective

● Blower defective

Replace blower (see Service Manual). Contact SICK Service.

Flow too low Air flow rate too low ● Air intake and/or exhaust air line blocked

● Pressure sensor and/or regulation of flow measure-ment option defective

● Air filter contaminated● Coarse filter contaminated

Check air intake and exhaust air lines, clean when necessary (→ p. 93, §5.2.1).

Check flow rate. Clean air / coarse filter and replace when neces-

sary (→ p. 94, §5.2.3, → p. 94, §5.2.4 Check flow measurement. Contact SICK Service.

Fuse holder


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6 . 3 Control unit

6.3.1 Malfunctions

6.3.2 Warning and error messages in SOPAS ET

Figure 89 "Diagnosis/Error Messages/Warnings" directory

The following malfunctions can possibly be cleared onsite.

Symptom Possible cause Action

No display on the LC-Display (option)

● No supply voltage● Cable to LC-Display not connected or

damaged● Defective fuse

Check voltage supply. Check connection cable. Exchange fuse. Contact SICK Service.

Description Display


AO configuration The number of optional modules does not match the number of analog outputs configured.

● No parameters set for AO● Connection error● Module failure

Check configuration (→ p. 67, §4.2.5).


AI configuration The number of optional modules does not match the number of analog inputs configured.

● No parameters set for AI● Connection error● Module failure

Check configuration → p. 69, §4.2.6).


DO configuration The number of optional modules does not match the number of digital outputs configured.

● No parameters set for DO● Connection error● Module failure

Check configuration → p. 76, §4.3.1).



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Figure 90 "Overview" directory

Sensor configuration The number of available sensors does not match the number of con-nected sensors.

● Sensor failure● Communication problems

on RS485 line

Check sensor addressing and availability (→ p. 102, Fig. 90).

Correct sensor selection (→ p. 76, Fig. 70).


Interface Module No communication via Interface module

● No parameters set for module

● Connection error● Module failure

Check configuration (→ p. 81, §4.3.2.2).


Variant configuration error

MCU setting does not connected sensor

Sensor type has been changed

Correct application settings (→ p. 64, §4.2.1).

Testmode enabled MCU in "Test" mode. Deactivate "System Test" mode ("Maintenance" directory)



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6.3.3 Replacing the fuse

MCU in wall housing

Disconnect the measuring system from the mains.

Open the door of the MCU control unit.

Remove and open the fuse holder.

Replace the defective fuse (→ p. 116, §7.6).

Close and attach the fuse holder.

Close the door and connect mains voltage.

Figure 91 Replacing the fuse

Fuse holder

Microfuse


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Control unit in 19” rack

Disconnect the measuring system from the mains.

Pull control unit out of the 19” frame.

Open fuse holder (1) (on the rear side of power supply unit (2)).

Replace the defective fuse (→ p. 116, §7.6).

Close fuse holder.

Insert control unit and reconnect the mains voltage.

Figure 92 Replacing the fuse

2 1 2 1

Power supply unit with plug-in connection Power supply unit with terminal connection


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VICOTEC450

7 Specifications

Technical Data

Dimensions, Part Nos.

Installation accessories

Options

Consumable parts for 2-year operation

Spare parts

Password


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7 . 1 Technical Data

Measured value recordingMeasured variable Scattered light intensity, computed to visibility (k value)Measuring range k value 0 ... 150/km; freely selectable Repeat accuracy ±2% of upper measuring range valueResolution Approx. 0.1/kmResponse time 1 ... 600 s; freely selectable (without dwell time for air suctioned in the air intake line) Measuring delay Dwell time in air intake hose = line length [m] / air intake rate [m/s]Air intake rate Approx. 3 m/s for air intake hose inner diameter 13 mm and air intake hose length max. 30 mTemp. measurement (option) Measuring range -50 ... +250 °C; accuracy (not calibrated) ± 2 K; resolution ± 0.25 KFunction checkAutomatic self-test Contamination, drift, aging

Contamination limit values: 30% for warning; 50% for malfunctionManual linearity check With reference filterOutput signals Analog output 0/2/4 ... 20 mA, max. load 750 Ω; resolution 10 bits; electrically isolated

Further analog outputs when using I/O modules (option, → p. 22, §2.2.4)Relay outputs 5 potential-free outputs (changeover contact) for operation/malfunction status signals, mainte-

nance, function check, maintenance request, limit value; contact load 48 V, 1 A; further relay outputs when using I/O modules (option, → p. 22, §2.2.4)

Input signalsAnalog inputs 2 inputs 0 ... 5/10 V or 0 ... 20 mA (standard, without electrical isolation); resolution 10 bits;

further analog inputs when using I/O modules (option, → p. 22, §2.2.4)Digital inputs 4 inputs for connection of potential-free contacts (e.g. to connect a maintenance switch or trigger

a check cycle)Further digital inputs when using I/O modules (option, → p. 22, §2.2.4)

Communication interfaces USB 1.1, RS 232 (on terminals) For measured value inquiries and software updates per PC/laptop using the operating program RS485 To connect measuring unit(s)Interface module option To communicate with the Host PC, optional for Profibus, EthernetPower supplyVCME Operational voltage: 24 V DC

90 ... 250 V AC; 50/60 Hz with integrated optional power supply unitPower input: Max. 35 W

MCU Operational voltage: 90 ... 250 V AC; 50/60 Hz Power input: Approx. 50 W for VCME power supply

Ambient conditionsTemperature range –30 ... +55 °C Storage temperature –40 ... +60 °CProtection class IP 66 (after correct installation)MassVCME Approx. 12 kg (stainless steel housing 1.4571)MCU Approx. 5 kg (stainless steel housing 1.4571)Misc.Laser Laser class 2; power < 1 mW;wavelength approx. 650 nm;

service life approx. 100,000 h (MTBF) at 20 °CElectrical safety In accordance with EN 61010-1Blower output Approx. 30 ... 35 l/min


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7 . 2 Dimensions, Part Nos.All dimensions are specified in mm.

7.2.1 Measuring unit

Figure 93 Measuring unit

30032

0

300

215260

Ø 25 Ø 16Ø 9

Name Part No.

VCME-24-N-0-N measuring unit 1040575

VCME-24-N-0-F measuring unit 1040691

VCME-WR-N-0-N measuring unit 1040692

VCME-WR-N-0-F measuring unit 1040693

340

Type code → p. 18, §2.2.3


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7.2.2 Air inlet with protective grating

Figure 94 Air inlet with protective grating

Name Part No.Air inlet with protective grating for wall fitting 2040848Air inlet with protective grating for intermediate ceiling fitting 2040875

Ø 5,5

75 95 104

95

75

32

2

For wall fitting

For fitting on intermediate ceiling

Dimensions and assembly dimensions as for wall fitting design

.


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7.2.3 Cover with integrated air inlet

Figure 95 Cover with integrated air inlet from the side

Figure 96 Cover with integrated air inlet from below

115

248

297

99

120

Component Part No.Cover with integrated air inlet 2040850

Air inlet

Component Part No.Cover with integrated air inlet concealed 2061799

Air inlet

AA


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7.2.4 Cover for connections option

Figure 97 Optional cover for connections

115

248

297

9912

0

Name Part No.Cover for connections option 2040849


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7.2.5 Optional installation plate

Figure 98 Installation plate option

385

355

192.5 (6) 16

3331

0

310

350

∅ 12

∅ 12

∅ 12

Area for mounting the measuring unit

15

Name Part No.

Installation plate 2040856


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7.2.6 MCU control unit

Figure 99 MCU control unit in wall housing (shown with Display module option)

Figure 100 MCU control unit in 19” rack ((shown with Display module option)

210

160

340

320

300

125

Name Part No.

MCU-NWSN control unit 1046298

MCU-N2SN control unit 1046299

MCU-NWSD control unit 1046113

MCU-N2SD control unit 1046115

132.

5

57.1

5

465.9

482.6

180

Name Part No.

MCU-NWTD control unit in 19” rack 1046288

MCU-N2RD control unit in 19” rack 1046116


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7.2.7 Optional connection box for connection cables

In aluminium housing

Figure 101 Connection box

In stainless steel housing

Figure 102 Connection box in stainless steel housing

Fastening holes

113

80 52

5710

125

Ø 4.8

Name Part No.

Connection box 2046418

50

150

176

200

132

159

(210

)

84

Ø 9

Name Part No.

Connection box in stainless steel housing 2048067


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7 . 3 Installation accessories

7.3.1 Air intake and exhaust air hoses

7.3.2 Connection cable

7.3.3 Fastening sets

Name Part No.

Air intake and exhaust air hoses, set, length 5 m 2042078



Name Part No.

Connection cable for VCME to MCU connection, length 5 m 7042017



Name Part No.

Fastening set 4D8-1.4571/PA 2031889

Fastening set 2D4-1.4571/PA 2031890

Fastening set 2M8-1.4571 2031891

Fastening set 4M8-1.4529 2031887


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7 . 4 Options

7.4.1 VCME measuring unit

7.4.2 MCU control unit

7.4.3 Accessories for device check

Name Part No.

Power supply unit 24 V DC, 75 W 2050635

Temperature measurement with 1x temperature sensor Ni-Cr-Ni, electronics module and line length 20 m (standard length)

2040852

Temperature measurement with 2 x temperature sensor Ni-Cr-Ni, electronics module and line length 20 m (standard length)

2040853

Name Part No.

Options for MCU control unit

Analog input module, 2 channels, 100 Ω, 0/4...22 mA, electrically isolated (80 V difference)

2034656

Analog output module, 2 channels, 500 Ω 0/4 ... 22 mA, electrically isolated per module

2034657

Digital input module, 4 channels, for potential-free contacts, max. 4.5 mA 2034658

Digital output module, power relay2 changeover contacts, contact load 48 V AC/DC, 5 A

2034659

Digital output module, signal relay,4 NO contacts, contact load 48 V AC/DC, 0.5 A

2034661

Additional options for MCU control unit in wall housing

Module carrier (each for one AI, AO, DI or DO module) 6028668

Connection cable for optional I/O modules 2040977

Profibus DP V0 interface module 2040961

Ethernet interface module 2040965

Additional options for MCU control unit in 19” rack

I/O module carrier 19” (for installation of up to 4 AI/AO and DI/DO modules) 2050589

Interface module 19” Profibus DP 2049334

Interface module 19” Ethernet 2048377

Name Part No.

Check filter set for VICOTEC450 2043331


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7 . 5 Consumable parts for 2-year operation

VCME measuring unit

7 . 6 Spare parts

Name Qty. Part No.

Filter insert C1140 (only old versions with blower 6033052)

2 7047560

Filter insert C 630 2 5324368

Coarse filter (for air inlet with protective grating) 2 4050450

Optics cloth 2 4003353

Name Part No.

Measuring unit

Knurled nut M4 5313198

Socket 7-pole (to connect connection cable to MCU) 7045569

Socket 4-pole (to connect mains voltage to measuring unit with optional power supply unit)

7045613

Fuse set T2A 2054541

Control unit

Fuse set T2A (for MCU with mains voltage supply) 2054541

Fuse set T4A (for MCU with 24 V supply) 2056334


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7 . 7 Password

Passwort „Autorisierter Nutzer“Nach dem Start des Bedien- und Parametrierprogrammes SOPAS_ET sind nur die Pro-grammfunktionen verfügbar, die keinen Einfluss auf die Gerätefunktion haben.

Nicht eingewiesenes Personal kann keine Änderungen der Parameter vornehmen. ZurNutzung des erweiterten Funktionsumfanges wird das

Passwort benötigt.

Falls zur Eingabe eine falsche Taste gedrückt wird, muß das Fenster geschlossen undanschließend die Passworteingabe wiederholt werden.

Password "Authorized Operator"

After the start of the SOPAS_ET operating and parameterization program, only menusare available which have no effect on the functioning of the device.Untrained personnel cannot alter the device parameters. To access the extended rangeof functions the

password must be entered

If a wrong key is pressed when entering the password, the window must be closed andthen the entering repeated.

SICKOPTIC

SICKOPTIC


SICK AG | Waldkirch | Germany | www.sick.com

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1 (800) 325-7425 – tollfree E-Mail [email protected]

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8011767 OI VICOTEC 450 en V2-2 2013-02 - SICK